Nelson INTRA 2100 User Manual

Operating manual
Stud welding unit
INTRA 2100/1400
for
drawn arc and short-term drawn arc processes
Edition:
2021-07
Revision:
Rev. A / 07.2021 / EN
EN
Document number

Nelson INTRA 2100 Specifications

General

Brand	Nelson
Model	INTRA 2100
Category	Welding System
Language	English

Summary

1 Introduction

1.1 General remarks

General information about the operating manual and the INTRA 2100/1400 welding device.

1.2 Device description

Overview of the INTRA 2100/1400 welding device, its features, and capabilities.

1.3 Description of stud welding process

Explanation of the drawn arc and short cycle stud welding processes.

1.4 Material combinations

Information on compatible material combinations for stud welding.

1.5 Technical data

Technical specifications for the INTRA 2100 and INTRA 1400 models.

1.6 Accessories (optional)

List of optional accessories available for the welding unit.

1.7 Declaration of Conformity

Official declaration of the product's compliance with EU directives.

2 Work safety

2.1 Safety symbols

Explanation of safety symbols used in the manual and their meanings.

2.2 Safety instructions

Crucial safety instructions for operating and handling the welding device.

2.3 Intended use

Defines the correct and safe application of the welding device.

2.4 Warranty and liability

Information regarding warranty conditions and manufacturer's liability.

2.5 Copyright

Legal notice regarding the copyright of the documentation.

3 Delivery and transport

3.1 Scope of delivery

Details the items included in the INTRA 2100/1400 welding device package.

3.2 Packaging and dispatch

Information on packaging and dispatch regulations.

3.3 Incoming inspection

Instructions for inspecting the device upon delivery for damage.

3.4 Interim storage

Guidelines for temporary storage of the welding device.

3.5 Transport

Safe methods and precautions for transporting the welding device.

3.6 Location of use

Specifies suitable and unsuitable locations for operating the device.

3.7 Device set-up

Instructions and safety precautions for setting up the welding device.

4 Connection tasks

4.1 Power cable connection

Step-by-step guide for connecting the power cable safely.

4.2 Welding gun connection

Instructions for connecting the welding gun to the control device.

4.3 Earth cable connection

Guide for properly connecting the earth cables.

4.4 Workpiece connection

How to connect the earth clamps to the workpiece.

5 Operating and display elements

5.1 Operating elements

Overview of controls like power switch, potentiometers for weld current/time, and mode selector.

5.2 Display elements

Explains the meaning of LED indicators for status and troubleshooting.

6 Start-up and weld quality check

6.1 Notes about stud welding

Important notes and tips for achieving good weld joints.

6.2 Adjusting the weld parameters

How to set electrical and mechanical parameters, including data for drawn arc and short cycle processes.

6.3 Commissioning conditions

Checks and conditions required before starting operation.

6.4 Functional test

Procedure for performing a functional test of the welding system.

6.5 Checking weld quality

Methods for inspecting weld quality, including visual and mechanical tests.

7 Maintenance

7.1 Care and cleaning

Instructions for cleaning and maintaining the welding device.

7.2 Maintenance intervals

Recommended schedule for maintenance tasks.

8 Repairs

8.1 Notes on repair

General instructions and warnings before performing repairs.

8.2 Troubleshooting

Guide to diagnosing and resolving common faults.

8.2.1 Fault: Power supply

Troubleshooting steps for power supply related issues.

8.2.2 Fault: Overload/phase error

Troubleshooting steps for overload and phase errors.

8.2.3 Fault: Gun function

Troubleshooting steps for issues related to the welding gun function.

8.2.4 Fault: Welding

Troubleshooting steps for welding-specific faults.

8.2.5 Electronics error search

Guide to diagnosing electronic errors using LED indicators.

9 Appendix

9.1 Disposal of the welding device

Guidelines for the proper disposal of the welding device and its components.

9.2 Abbreviations

Alphabetical list of abbreviations used in the documentation.

9.3 Bibliography

List of bibliographic sources referenced in the manual.